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Eaton AT-1202, Service Manual

The Eaton AT-1202 Installation Manual is a comprehensive guide designed to assist users in seamlessly installing and optimizing their AT-1202 product. This detailed manual can be easily downloaded for free from manualshive.com, providing users with step-by-step instructions and troubleshooting tips to ensure a successful installation.

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Torque

7

Gen

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ra

l Inf

o

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at

ion

Torque Ratings

Recommended torque ratings, location and thread sizes of capscrews and nuts are listed below. Capscrew lengths are given for
reference purposes as a guide for installation at proper locations.

Correct torque application is extremely important to assure long transmission life and dependable performance. Over-tightening
or undertightening can result in a loose installation and in many instances, cause damage to transmission gears, shafts and bear-
ings. Do not torque capscrews dry.

Note: 

Installing the capscrews with more than 23 lbs. ft. of torque will force the corners of the PTO cover away from the case with

resultant oil leakage.

Capscrews

Location

Quantity

Thread Size and Length

Torque Rating Foot-Pounds

PTO cover, large

8

7/16 - 14x 1

50 - 65 lbs. ft.

PTO cover, small

6

3/8 - 16x 3/4

18-23 lbs. ft. (12-15 lbs. ft.
with oil filter)

Countershaft Front Bearing
Covers

8

3/8  -  16x  1

Countershaft Rear Bearing
Covers

8

3/8  -  16x  3

Rear Plate to Front Case

16

3/8 - 16x 1 - 1/2

1

3/8 - 16x 3 

35-45 lbs. ft.

2

3/8  -  16x  2

Rear Bearing Housing

5

3/8 - 16x 3

1

3/8 - 16x 3 eslock

Shift Bar Housing

4

3/8 - 16x 1 - 1/4

Nuts

Location

Quantity

Thread Size and
Length

Torque Rating 

Mounting Studs 4

5/8 - 18

170 - 185

Front Bearing
Housing

6

1/2  -  20

Companion
Flanges or
Yokes

2

2 3/4 - 16

450 - 500

Summary of Contents for AT-1202

Page 1: ...Service Manual Eaton Fuller Heavy Duty Transmissions TRSM0996 EN US April 2019 AT 1202 Models ...

Page 2: ... reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalents may be used This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage Departure from the...

Page 3: ... use with heavy duty transmis sions This auxiliary transmission contains two sets of gears thus giving the reduction low ratio when power is delivered through these two sets of gears The other speed is obtained by direct high drive through the auxiliary A single shift bar in the right side of the case controls speed changes ...

Page 4: ...s two on each side of case Gear Ratios Direct 1 00 Reduction 2 036 Power Take OFF Bottom SAE Standard 6 bolt 30 tooth 5P gear on left coun tershaft turning at 993 input shaft speed Top SAE Standard 8 bolt 30 tooth 5P gear on right coun tershaft turning at 993 input shaft speed Weight 330 pounds Oil Capacity 12 pints Installation length 16 3 16 inches Shift Positions Nuetral Direct Reduction ...

Page 5: ...ion Worldwide Marketing Services P O Box 4013 Kalamazoo MI 49003 Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrication will occur The operating angle is the transmis sion mounting angle in the chassis plus the percent of upgrade expressed in degrees For operating angles over 12 degrees the transmission must be equipped with an oil pump or co...

Page 6: ...ade and oil capacity 3 Gear Shift Lever and Linkage Check the auxiliary gear shift lever for wear at mounting Check shifting linkage for wear and looseness Check to make sure exact neutral position of auxiliary gear shift lever corresponds to neutral position of auxiliary shifting bar 4 Capscrews and Nuts Check capscrews in top cover and bearing covers for looseness which might be the cause of oil...

Page 7: ...ol 8530 M 89 Richland MI 49083 Phone 800 877 9618 or 269 629 9628 General Tools Tool Purpose 0 100 lbs ft 1 2 drive Torque Wrench General torquing of fasteners 0 600 lbs ft 3 4 or 1 drive Torque Wrench Torquing of output nut Snap Ring Pliers large standard external To remove snap rings at the auxiliary drive gear input shaft bearing and countershaft Rolling Head Crow s foot prybar To remove the au...

Page 8: ...pscrews with more than 23 lbs ft of torque will force the corners of the PTO cover away from the case with resultant oil leakage Capscrews Location Quantity Thread Size and Length Torque Rating Foot Pounds PTO cover large 8 7 16 14x 1 50 65 lbs ft PTO cover small 6 3 8 16x 3 4 18 23 lbs ft 12 15 lbs ft with oil filter Countershaft Front Bearing Covers 8 3 8 16x 1 Countershaft Rear Bearing Covers 8...

Page 9: ...unit during repairs The outside of the unit should be carefully cleaned before starting the disassembly Dirt is abrasive and can damage highly polished parts such as bearings sleeves and bushings Bearings Carefully wash and re lubricate all bearings as removed and protectively wrap until ready for use Remove all bearings with pullers designed for this purpose Do not remove bearings with hammer and...

Page 10: ...or flange on each shaft and use a large breaker bar to remove the elastic stop nut from each shaft 2 Remove the washer and flange or yoke from each shaft Note If a special tool is not available the stop nuts may be removed by putting the transmission in direct gear installing a breaker bar on the stop nut of both input and output shaft and removing the nuts by bracing them against each other ...

Page 11: ... Rear Plate from the Front Case Special Instructions None Special Tools Typical service tools Procedure 1 Loosen the jam nut and turn the rod end from the end of the shift bar 2 Turn out the 19 capscrews attaching the rear plate to the front case ...

Page 12: ... screws in the three tapped holes in the mounting flange of the rear approximately 1 2 to break the gasket 4 Attach a chain hoist to the rear plate and move the plate evenly to the rear and off the front case dowel pins Mount the rear plate in a vise in the upright position ...

Page 13: ...ecial Tools Typical service tools 1 O ring 2 Shift Cylinder 3 Shift Piston Assembly 4 O ring 5 Roll Pin 6 O ring 7 Yoke Bar 8 Cylinder Cover 9 Gasket 10 Lockwasher 11 Capscrew 12 Shift Yoke 13 Lockscrew 14 Gasket 15 Elbow 16 Air Valve 17 Air Valve 18 Valve Plate 14 2 12 1 13 7 6 3 4 5 9 8 15 10 11 16 61 61 17 ...

Page 14: ...e 1 Cut the lockwire and remove the yoke lockscrew 2 Remove the spacer from the front of the shift bar 3 Put a rag over the bore in the shift bar housing to prevent loss of the tension spring and ball and pull the shift bar sharply forward and from the housing ...

Page 15: ...om the sliding clutch and remove the sliding clutch from the splines of the output shaft 5 Turn out the four capscrews attaching the shift bar housing to the rear plate and remove the housing l 6 Tip the housing to remove the tension spring and ball ...

Page 16: ...Control Assembly Without Air Special Instructions None Special Tools Typical service tools 1 Eye Rod end 2 Nut 3 Yoke Bar 4 Spacer 5 Shift Yoke 6 Lockscrew 7 Gasket 8 Shift Cylinder 9 Plug 10 Capscrew 11 Spring 12 Steel Ball 13 NLA Spacer 1 2 3 4 5 13 13 7 8 10 10 9 11 11 6 12 12 ...

Page 17: ...acer from the front of the shift bar 3 Put a rag over the bore in the shift bar housing to prevent loss of the tension spring and ball and pull the shift bar sharply forward and from the housing 4 Remove the yoke from the sliding clutch and remove the sliding clutch from the splines of the output shaft ...

Page 18: ...al and Disassembly 17 Removal and Disassembly 5 Turn out the four capscrews attaching the shift bar housing to the rear plate and remove the housing l 6 Tip the housing to remove the tension spring and ball ...

Page 19: ...Countershaft Assemblies Special Instructions None Special Tools Typical service tools Procedure 1 Use a three jaw puller or equivalent to remove the front bearing from each countershaft 1 Bearing 2 Welded Countershaft 3 Bearing 4 Snap Ring 1 2 3 4 ...

Page 20: ...Removal and Disassembly 2 Remove the two countershaft rear bearing covers 3 Remove the snap ring from the rear of each countershaft 4 Use a soft bar and maul to drive the countershaft assemblies forward and from the rear bearings ...

Page 21: ...Removal and Disassembly 20 5 Use a soft bar to tap the bearings to the rear and from the rear plate bores ...

Page 22: ...Reduction Gear Assembly Special Instructions None Special Tools Typical service tools Procedure 1 Use a soft bar and maul to drive the output shaft forward and from the rear bearing assembly 1 Sliding Clutch 2 Mainshaft 3 Reduction Gear 4 Bearing 5 Snap Ring 6 Washer 7 Nut 1 2 3 4 5 6 7 ...

Page 23: ...p ring from the groove in the I D of the re duction gear 4 Use a soft bar to tap the reduction gear from the output shaft 5 Using the inner race of the reduction gear bearing as a base press the rear bearing front cone from the output shaft This will free the reduction gear bearing and washer ...

Page 24: ...y 23 Removal and Disassembly How to Remove the Rear Bearing Assembly Special Instructions None Special Tools Typical service tools Procedure 1 Turn out the six capscrews attaching the rear bearing hous ing to the rear plate ...

Page 25: ...he front bearing cup and outer spacer forward and from the rear plate bore 4 From inside the plate tap the rear bearing cup to the rear and from the rear plate bore Note If necessary remove the oil seal from the rear bearing housing with a hammer and punch Removal proce dure will damage the seal and removal should not be attempted unless replacement of the seal is planned ...

Page 26: ...e the Input Shaft and Drive Gear Assembly Special Instructions None Special Tools Typical service tools Procedure 1 Remove the snap ring from the groove in the rear of the cou pling shaft 2 Pull the drive gear to the rear and from the splines of the coupling shaft ...

Page 27: ...d Disassembly 26 3 Use a soft bar and maul to drive the input shaft to the rear and from the front bearing assembly 4 Remove the snap ring from the input shaft 5 Press the input shaft rear bearing from the shaft ...

Page 28: ...readed end down and use a Allen wrench to remove the Allen screw located in the hub of the coupling shaft It will be necessary to turn the Allen wrench with a crescent or open end wrench Note Do not install the input shaft in the vise by the threads 7 Remove the coupling shaft from the input shaft ...

Page 29: ...y 28 How to Remove the Front Bearing Housing Assembly Special Instructions None Special Tools Typical service tools Procedure 1 Remove the six nuts attaching the housing to the front case and pull the housing from the studs ...

Page 30: ...e the oil seal or front bearing 3 If necessary remove the shifting bar packing and packing retainer from the front shifting bar bore in the case and re move the Welch plug from the rear shifting bar bore 4 If necessary remove the pipe plug from the bore in the top of the case ...

Page 31: ...For reassembly purposes remove the two countershaft front bearing covers Note Remove PTO gear covers filler and drain plugs breather and miscellaneous items as necessary Re moval of the seal and scraper in the shift bar bore will most likely damage the parts and removal should not be attempted unless replacement of the parts if planned ...

Page 32: ...spalled or damaged Lubricate bearings and check for axial and radial clearances Replace the bearings with excessive clearances Check fits of the bearings in the case bores If the outer races turn freely in the bores the case should be replaced Gears Check the operating gear teeth for pitting on the tooth faces Gears with pitted teeth should be replaced Check all engaging gear teeth both internal a...

Page 33: ...ball Check yoke for wear at pads and replace if worn Check yoke for excessive wear and replace if worn Bearing Covers Check the covers for wear from the thrust of adjacent bearing Replace the covers that are worn or grooved from the thrust of the bearing outer race Check bores of covers for wear and replace those worn oversize Oil Seals Check the lip seal in the front and rear for wear cracks or b...

Page 34: ...rt to be installed with adhesive to hold in place during installation Capscrews To prevent oil leakage use adhesive sealant on all capscrews See Torque Ratings chart on page 6 for recommended torque applications Initial Lubrication Coat gear bushings washers and splines of mainshaft with Lubriplate during installation to provide initial lubrication thus preventing scoring and galling Bearings Use ...

Page 35: ...stic stop nut is used With slotted type nut use 250 to 300 lbs ft of torque Make sure the speedometer gear has been installed between the rear flange and the bearing If the speedometer gear is not used a replacement spacer of the same width must be used Make sure the speedometer gear washer is installed between the speedometer gear and bearing Oil Filling Remember to fill the transmission with the...

Page 36: ...the input shaft in the vise by the threads Special Tools Typical service tools Procedure 1 Apply a drop of Grade AVV Loctite to the threads of the Allen head screw 2 Install the coupling shaft in the input shaft with the large bore facing up 3 Secure the coupling shaft to the input shaft with the Allen head screw It will be necessary to turn the Allen wrench with an open end or cresent wrench ...

Page 37: ...ll the rear bearing on the input shaft against the shoul der on the shaft Note Heating of the bearing will faciliate installation Do not heat the bearing over 275 F 2 Install the snap ring in the groove on the input shaft 3 Install the front bearing in the bearing housing with a bear ing driver or by tapping carefully on the bearing inner race with a soft bar ...

Page 38: ... bore 5 Use an oil seal driver to install the front oil seal The side of the oil seal with the seam should face into the housing and the front of the seal should be flush with the face of the housing 6 Install the front bearing housing on the front case studs with the oil feed port on the mounting surface of the bearing housing aligned with the oil port in the front of the case Se cure with the si...

Page 39: ... the rear bearing seats against the shoulder in the bore 8 Install the drive gear on the shaft with the clutching teeth facing towards the rear of the case 9 Install the snap ring in the groove on the coupling shaft Note If previously removed reinstall the two PTO covers all plugs and the shift bar seal and scraper Do not install the two countershaft front bearing covers at this time ...

Page 40: ...s Procedure 1 Install the reduction gear bearing in the hub of the reduction gear with snap ring in the bearing facing up Use a bearing driver or tap carefully on the outer race of the bearing with a soft bar 2 Install the snap ring in the groove in the hub of the reduction gear 3 Mark any two teeth on the reduction gear and then mark the two teeth directly opposite ...

Page 41: ...the clutching teeth of the gear facing down 5 Install the washer on the shaft and against the gear with the larger bevel on the ID of the washer facing down 6 Install the bearing front cone on the shaft and against the washer with the taper facing up Note Heating of the bearing will faciliate installation Do not heat the bearing over 275 F ...

Page 42: ...Assembly and Installation 41 Assembly and Installation 7 Install the bearing inner spacer on the shaft ...

Page 43: ...ools Typical service tools Procedure 1 Install the bearing front cup in the rear plate bore taper fac ing up 2 Place the bearing outer spacer on the front cup and tap even ly into the rear plate bore 3 Place the bearing rear cup on the outer spacer and tap evenly into the bore until the rear cup lip seats against the plate ...

Page 44: ... the cover holds the lip of the bearing cup against the rear plate 5 Install th e bearing rear cone on the shaft taper facing down Note Heating of the bearing will facilitate installation Do not heat the bearing over 275 F 6 If previously removed install the oil seal in the rear bearing housing flush with the surface seam of the seal facing into the housing Note On units equipped with a speedomete...

Page 45: ...brass washer is installed in the capscrew bore intersecting the speedometer bore Note The rear bearing housing may be installed with the speedometer bore on either the left or right hand side of the plate Make sure that either notch in the mount ing surface of the housing is lined up with the oil port in the mounting surface of the plate ...

Page 46: ...ecial Instructions None Special Tools Typical service tools Procedure 1 Mark the tooth which is stamped with an O on the reduction gear of each countershaft 2 Place one of the countershaft assemblies in position inside the plate with the marked tooth meshed between two of the marked teeth on the reduction gear ...

Page 47: ...and in the case bore 4 Use a bearing driver and maul to comlete installation of the countershaft rear bearing Repeat the procedure for installa tion of the remaining countershaft 5 Install the snap ring in the groove at the rear of each coun ershaft 6 Install the two countershaft rear bearing covers ...

Page 48: ...service tools Procedure 1 Install the tension spring in the bore of the shift bar housing 2 Install the tension ball over the spring and use a screwdriver or equivalent to hold the tension ball down and insert the end of the shift bar with the three notches into the housing until the neutral middle notch is over the tension spring and ball ...

Page 49: ...e facing the rear plate 4 Place ths shift housing and bar in position passing the shift bar through the yoke hub Note that the tension spring hous ing faces to the outside of the plate 5 Turn the shift bar until the lockscrew bore aligns with the lockscrew bore of the shift yoke A click will be heard when the tension ball seats in the neutral notch ...

Page 50: ...and lockwire securely 7 Install the spacer on the shift bar and against the yoke with the bevel on the ID of the spacer facing the yoke 8 Secure the shift bar housing to the rear plate with the four retaining capscrews If previously removed install the plug in the end of the shift bar housing ...

Page 51: ...ain hoist to the rear plate and move the plate evenly into the front case first guiding the shift bar into the front case bore and then installing the rear plate bores on the front case dowel pins Turn the input shaft as necessary to mesh with the countershaft assemblies 2 Secure the rear plate to the front case with the 19 retaining capscrews ...

Page 52: ...ation 3 Use a soft bar to start the countershaft front bearings on the shafts and into the case bores Use a bearing driver to com plete installation The beveled ID of each bearing faces into the case 4 Install the two countershaft front bearing covers ...

Page 53: ...Special Instructions None Special Tools Typical service tools Procedure 1 If previously removed install the jam nut on the rod end and turn the rod end into the end of the shift bar 2 Set the rod end in the desired position and lock in place by tightening the jam nut against the shift bar ...

Page 54: ...1 Install the yoke or flange on the input shaft and install the washer and elastic stop nut on the threads of the input shaft 2 On units not equipped with a speedometer drive gear install the spacer on the output shaft and in the rear bearing hous ing 3 Install the yoke or flange on the output shaft and install the washer and elastic stop nut on the threads of the shaft ...

Page 55: ...elastic stop nut on each shaft to 450 500 lbs ft torque Note If a special tool is not available the stop nuts may also be installed by putting the transmission in direct gear and bracing against one shaft while torquing the stop nut on the other shaft Repeat the procedure for torquing the opposite stop nut ...

Page 56: ...oducts with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www ...

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